EQSS Model6253 OverWatch™ I Genie GEN-5 N S T A L M A N U A L · DO0001195 Model6253 OverWatch™ User Manual CURRENT DOCUMENT REVISION: 2.0 REVISION INFORMATION: • 1.0 Initial

EQUIPMENT SAFETY SYSTEMS 75 Naxos Way, Keysborough 3173 Victoria Australia

P: +61 3 8770 6555 E: [email protected]

Genie GEN-5 Series Installation Manual

REV 2.0 24/09/2020 Model6253 OverWatch™ Installation Manual Document # DO001235

EQSS Model6253 – OverWatch™ Genie GEN-5

INSTALL

MANUAL

** Failure to follow this installation manual will void warranty **





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AUTHORS: Kieren Grogan, Jay Nandakumar, Truong Bui

AUTHORISED BY: Kieren Grogan

CHECKED BY: Kieren Grogan

DOCUMENT ABSTRACT: This Installation Manual details the manufacturer’s installation instructions for installing the Model6253 OverWatch™ on a Genie GEN-5 scissor lift.

PRODUCT NAME: Model6253 OverWatch™ Operator Detection System

REFERENCE DOCUMENTS: DO0001195 Model6253 OverWatch™ User Manual

CURRENT DOCUMENT REVISION: 2.0

REVISION INFORMATION:

• 1.0 Initial Document Creation for installation on a Genie Gen5

• 1.1 Changed layout of installation manual and corrected wiring colours

• 1.2 Updated to include wire harness images

• 2.0 Updated location of drive and elevate signal





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Important Information

Information contained in this publication regarding this device’s applications and the like, is provided only for your

convenience and may be superseded by updates. It is your responsibility to ensure that the application or our

equipment meets with your specifications.

EQUIPMENT SAFETY SYSTEMS MAKE NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, WHETHER EXPRESSED OR

IMPLIED, WRITTEN OR ORAL, STATUTORY OR OTHERWISE, RELATED TO THE INFORMATION, INCLUDING, BUT NOT

LIMITED TO, IT’S CONDITION, QUALITY, PERFORMANCE, MERCHANTABILITY OR FITNESS FOR PURPOSE.

Equipment Safety Systems disclaims all liability arising from this information and its use. Use of Equipment Safety

Systems’ products as critical components in life support systems is not authorised except with express written

approval by Equipment Safety Systems. No licenses are conveyed, implicitly or otherwise, under any Equipment Safety

Systems intellectual property rights.

This is a class A product certified to AS/NZS CISPR 22:2006. In a domestic environment this product may

cause radio interference in which case the user may be required to take adequate measures.





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Table of Contents Preparation ........................................................................................................................................... 5

Required Tools ................................................................................................................................. 5

Installation Time .............................................................................................................................. 5

Installation Instructions ........................................................................................................................ 6

Operator Sensor................................................................................................................................ 6

Control Module ................................................................................................................................ 9

Post Installation Configuration .......................................................................................................... 17

Overview ........................................................................................................................................ 17

Minimum system requirements ...................................................................................................... 17

Wi-Fi Connection & Web Page Access ......................................................................................... 17

Machine Model Selection .............................................................................................................. 18

Installation Test .............................................................................................................................. 19

Change Model Configuration......................................................................................................... 20

System Settings .................................................................................................................................. 21

Default Settings .............................................................................................................................. 21

Polarity and Input Style.................................................................................................................. 23

Bypass ............................................................................................................................................ 23

Connection Schematics – Typical Application .................................................................................. 24





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Preparation

Required Tools The OverWatch™ has been designed to be fitted using basic workshop tools. Shown below is a list of tools required to complete the installation

Item Tool / Description

1 Electric Drill

2 Centre punch

3 Hammer

4 Side Cutters

5 Drill 3.2mm

6 Drill 5.0mm

7 Metric sockets or spanners

8 Needle nose pliers

9 Screw drivers

Installation Time The suggested time required to install the OverWatch™ is as detailed below

Task Estimated Time (Minutes)

Open the operator control box 1

Drilling of all mounting holes for the various components 13

Mechanical assembly 10

Electrical assembly 30

Post installation system tests 10

Close the operator control box 1

Total 65





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Installation Instructions

Operator Sensor

Step Description Diagram

1. Drill two 5.0mm holes to mount the operator sensor in the position shown in the diagram.

The sensor should be mounted at an angle of 40 degrees.

Drill a 4.0mm hole for the P-Clip installation.

2. Mount the Operator Sensor in the located position using the supplied angled wedges, sensor guard, M4 washers, nuts and bolts.





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3. Remove the bottom cover of the joystick enclosure.

4. Install the Operator Sensor cable gland in the location shown by drilling a 20mm hole.

50.00mm





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5. Route the operator sensor cable as shown in the diagram.





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Control Module

Step Description Diagram

1. To mount the ECU module, drill the holes shown in the diagram. Use the supplied bolts and nuts to mount the ECU module to the inside of the control box.





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2. Wiring connections are made by the OverWatch™ Harness AS001955.





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3. Ground Connection:

Solder the Black Ground wire from the OverWatch™ ECU Harness to the White wire (Ground) from the main connector.

4. Power Connection:

Install the Red wire from the OverWatch™ ECU harness to the E-stop switch connector terminal 1.





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5. Trigger Connection:

Locate the Orange wire from the harness coming from the joystick (14 pin connector) and cut it in half.

Solder the Green wire from the OverWatch™ ECU harness to the Orange wire on the side that is coming from the joystick.

Solder the Blue wire from the OverWatch™ ECU harness onto the connector side of the wire that was cut.

6. Joystick Connection:

Solder the Grey wire from the OverWatch™ ECU harness onto the Yellow wire coming from the joystick.

7. Remove the buzzer and the E-Stop button to have better access to the main circuit board.





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8. Identify the pin locations on the circuit board shown in the image. Detailed instructions on soldering locations will be displayed in the following steps.

Carefully remove the protective coating on the circuit board to expose the through hole push button switch pads as shown in the image. The protective coating can be removed by using a small pick.





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9. Drive Select Connection:

Solder the Purple wire from the OverWatch™ ECU harness to the pin behind the Drive Select button as shown in the image.

10. Elevate Select Connection:

Solder the Orange wire from the OverWatch™ ECU harness, to the pin behind the Elevate Select button as shown in the image.





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11. Horn Connection:

Solder the white horn wires from the OverWatch™ ECU harness to the pins shown in the photo.





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12. Use hot glue to cover the soldered locations.

Use the 6.3mm P-clip provided to secure the wires as shown in photo.

13. Connect the 8-Pin connector from the Operator Sensor and the 12-Pin connector from the machine harness to the control module.





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Post Installation Configuration

Overview After the OverWatch™ has been installed it must be configured with the parameters to suit the machine. Follow the instructions below to configure the OverWatch™.

Minimum system requirements

Any smart phone, tablet or laptop that meets the following requirements:

• The device can connect to a Wi-Fi access point supporting 802.11 b/g/n (2.4GHz) protocol

• The device has an up to date web browser installed (2019 onwards). Firefox or Chrome are recommended. Note: Microsoft Internet Explorer is not supported.

Wi-Fi Connection & Web Page Access To enable the Wi-Fi connection on the OverWatch™ to complete the configuration follow the steps below.

1. Power down the platform control box with the ESTOP

2. Wait 10 seconds

3. Power up the platform control box with the ESTOP

4. While standing in the operator position, switch on the OverWatch™

5. As the welcome chime starts to play, cover the sensor. The LED will flash white then black to acknowledge.

6. Remove your hand from the sensor. The LED will flash white then black to acknowledge.

7. After covering then uncovering the sensor this way 2 more times, "Wi-Fi On" will be announced

8. On your Wi-Fi enabled device (laptop, tablet, smartphone, etc), show the available wireless networks

9. Select the wireless network (starts with “overwatch”) to connect to the OverWatch™

10. When prompted, enter the password “12345678”

11. Open your preferred web browser (Chrome, Firefox)

12. Enter the following into the address bar http://192.168.4.1 to open the OverWatch™ main page

http://192.168.4.1/





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Machine Model Selection Follow the instructions below to configure the OverWatch™.

1. Select the Setup option

2. If there is a password field at the bottom of the page, follow the instructions in Change Model Configuration to obtain the password and enter the password field

3. Select the EWP Model from the drop-down list and click Set

4. Click on Proceed to Test to begin the installation test

Genie Gen 5

Genie Gen 5

Genie Gen 5





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Installation Test After the model configuration has been set or updated an Installation Test must be performed. This will ensure the installation has been correctly performed and the OverWatch™ is functioning correctly.

Follow the instructions on the web page to complete the Installation Test.





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Change Model Configuration To reconfigure the OverWatch™ for a different model requires an authorisation password to be supplied by a service manager. The authorisation password is generated from the EQSS website. The EQSS website requires a login username and password. If you are a service manager and do not have a username and password, contact EQSS to register. Follow the instructions below to obtain an authorisation password.

1. Open your preferred web and enter the following into the address bar http://www.eqss.com.au/overwatch to open the Login page

2. Select Customer

3. Enter your username and password

4. Ask the service technician for the serial number shown on the Setup page or on the ECU module along with the owner details of the EWP and complete the details form then click Generate Hash

5. Provide the 5-digit hash password to the service technician

Genie Gen 5

http://www.eqss.com.au/overwatch





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System Settings

Default Settings See the sections below for details on each of the Genie GEN-5 Series OverWatch™ default system settings.

Setting Name Description Default

deltaseek This specifies which of the previous lidar reading to compare against the current one to calculate the speed.

20

max_safe_velocity This is the velocity threshold for the cutout in cm/s. for drive mode.

105

max_safe_displacement This is the maximum permitted distance in cm the operator may be away from the calibration position in drive mode.

60

max_safe_velocity_elevate This is the velocity threshold for the cutout in cm/s. in elevate mode.

95

max_safe_displacement_elevate This is the maximum permitted distance in cm the operator may be away from the calibration position in elevate mode.

50

max_safe_velocity_neutral This is the velocity threshold for the cutout in cm/s. in neutral mode.

60

max_safe_displacement_neutral This is the maximum permitted distance in cm the operator may be away from the calibration position in neutral mode.

40

fwddispadj The coefficient to apply to the displacement when the displacement is toward the sensor.

-0.8

fwdveloadj The coefficient to apply to the velocity when the displacement is toward the sensor.

-1

zone_obstruction

If the lidar sensor reading is below this, the lidar is considered to be obstructed (with paint or thick coat of dust) and the system is cutout until the obstruction is cleared.

5

zone_minimum Any lidar reading below this will trigger a cutout with the message: “Operator Zone”

15

zone_maximum Any lidar reading above this will trigger a cutout with the message: “Operator Zone”

120

horn_count_max The number of times the horn will sound when alerting the operator if the trigger remains pressed during the cutout.

2

horn_time_ms The amount of time in milliseconds each individual horn should play.

200

adc_elevate_threshold For the elevate ADC input, a reading above this indicates the EWP is in elevate mode.

300





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adc_drive_threshold For the drive ADC input, a reading above this indicates the EWP is in drive mode.

300

adc_trigger_threshold For the trigger ADC input, a reading above this indicates the trigger is pressed.

100

adc_joystick_fwd_threshold For the joystick ADC input, a reading above this indicates the joystick has been pushed forward.

1400

adc_joystick_bwd_threshold For the joystick ADC input, a reading below this indicates the joystick has been pulled backward.

1600

override_cooldown The amount of time in milliseconds the system will wait before accepting another override request.

20000

override_time The amount of time in milliseconds the override will last before it expires, and normal operation is resumed.

15000

override_listening_time

The amount of time in milliseconds the system will wait while the deadman is held down before considering it not to be part of the triple click override request.

300

override_reset_time

The amount of time in milliseconds the override system will wait before resuming listening after the deadman has been released at the end of an override period.

500

override_triple_click_time The amount of time in milliseconds 3 clicks of the deadman needs to occur in order to trigger the override.

2000

lidar_fault_timeout The amount of time in milliseconds of silence from the sensor module before a fault condition is triggered.

1000

cutout_fault_timeout The amount of time in milliseconds a discrepancy between the cutout and the cutout sensor is permitted before a fault condition is triggered.

3000

throttle_time Period after the trigger is pressed, the system does not track velocity.

2000

time_before_welcome Time after power on before welcome audio is played 250

stuck_displacement How much movement is considered to be non operator movement / trapped

20

stuck_time Period, after cutout to determine if the operator is not moving and is trapped

5000

stuck_time_long After the stuck time this is the interval between horn alerts

10000

wifi_on_click_count The number of times the trigger needs to be pressed after startup to enter Wi-Fi mode.

10

wifi_on_click_time The timeout after startup before OverWatch stops listening to the trigger click method of turning on the Wi-Fi

10000





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wifi_on_gesture_count The number of times to cover and uncover the sensor to enter Wi-Fi mode.

3

wifi_on_gesture_time The timeout before OverWatch stops waiting for the next part of the gesture in milliseconds

3000

wifi_on_gesture_initial_time The timeout after startup before OverWatch stops waiting for start of the gesture in milliseconds

10000

driving_state_timeout Mode selection switch timeout 7000

Polarity and Input Style The table below describes each setting

Setting Name Description Default joystick_drive_forward Direction of joystick to move EWP forward forward

joystick_elevate_upward Direction of joystick to move EWP upward forward

joystick_neutral_move Direction of joystick that requires monitoring when in neutral

forward

elevate_polarity Direction of signal logic low

drive_polarity Direction of signal logic low

trigger_polarity Direction of signal logic low

joystick_polarity Direction of signal logic low

neutral_safe Monitor when no drive mode set yes

driving_state_input Direct, timer based or separate joysticks timer

Bypass

Setting Name Description overwatch_state Redundant active

test_deadman_state Test channel enabled for primary cutout bypassed





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Connection Schematics – Typical Application

Documents

EQSS Model6253 OverWatch™ I Genie GEN-5 N S T A L M A N U A L · DO0001195 Model6253 OverWatch™ User Manual CURRENT DOCUMENT REVISION: 2.0 REVISION INFORMATION: • 1.0 Initial